VIRTUAL FACTORY

A Virtual Factory is simply defined as an integrated

simulation model of major subsystems in a
factory that considers the factory as a whole and
provides an advanced decision support capability.
It seeks to go beyond the typical modeling of one
sub-system at a time, such as the manufacturing
model the business process model and the
communication
network
model
developed
individually and in isolation.
It provides a link between the organization Brain
and all of the machines and devices on the factory
floor.

CHARACTERISTICS OF A
VIRTUAL FACTORY
--------------------------------

The Virtual factory is a mock-up of real factory

floor.
It supports the analysis and design of the logistics
of material movement, process flow and control
associated with manufacturing.
Ideas can be modeled on the computer before
there are built.
Models provide simulation, 3D visualization and
animation of machine operations to understand
complex behaviors.

ADVANTAGES OF VIRTUAL
FACTORY

Improved decision-making
Improved Operation efficiency
Flexibility
Streamlining lead times
Decrease in capital investment, inventories etc.
Facility Sizing
Equipment layout
Improved profitability
Can be used to perform time studies, human
accessibility/ ergonomics etc.

CHALLENGES FACING VIRTUAL

FACTORY
Inexperienced users
Security issues
Expensive
Resistance to change

DIFFERENT LEVELS OF
VIRTUAL FACTORY

Top Level
The top level is the factory implementation with machines,
transportation, control and scheduling models.

Intermediate Level
The intermediate level is the machine level implementation where
each machine can be controlled and loaded with parts and
appropriate codes. In such a model, it will be possible to Touch
the
machines,
control,
Knobs
and
see
actual
functionality.

Micro Level
The virtual factory will integrate process simulations such as metal
chip formation with given definition of tool geometry simulation of
chatter, tool wear etc.

APPROACHES

Downward Approach
It is initiated by a large vertically integrated company seeking
to reduce costs associated with fixed asset and to maintain
focus on key operations. Outsourcing breaks down the
companys vertical structure.

Lateral Approach :
In small specialized enterprises firm that is in the interest of
seeking strategic alliances, form partnership along a value
added chain (e.g., suppliers, manufactures and distributors).

FIGURE IN DETAILS

STOCK CONTROL SYSTEM

As we all know stock costs money. So a

business does not want to hold as huge
amount of stock, but neither nor do they want
to run out of stock. The way this balance between
too much and too little stock is handled is to
make use of a stock control system.

Stock management is concerned with having the

right level of stock so in order to satisfy
customer needs, and to manage the stock
i.e., identify excess or obsolete stock. The term
Stock control system can be used to include
various aspects of controlling the amount of stock
on the shelves and in the warehouses and how

CHARACTERISTICS OF SCS

A stock control system is a database

application.
There are many commercial stock control
systems available.
If the company has to handle a few stock
items,
a
simple
hand
managed
spreadsheet is sufficient.
However, if the company to need to handle the
stocks of a huge complicated company then it
may invest in a be spoke database system.

PROCESS OF
STOCK CONTROL SYSTEM
1.

Review current stock levels and sales volume of stock

items.
Determine the current level of stock held along with its value.
Analyze the sales record to ascertain which item are good sellers and
which are slow moving.
Focus more efforts on the aforesaid items for improved profit.
Update stock records with the current levels and have a policy to track
all movement of stock.

2.

Establish a stock control policy

Identify stock needed the most and ensure customers are never
disappointed.
Lighten the process of buying stock, keeping a track that the right level of
stock is maintained.
Negotiate best deals with suppliers (volume-based discounts, discounts
for quick settlement etc.)

Continue
Identify other areas of the business that have an
impact on stock management.

3.

Ordering Policy
Advertising and promotion will have an impact on stock levels.
Sales policies can have a strong influence on stock levels.
Delivery to customers can effect stock holdings.

ADVANTAGES OF SCS

Proper record of a particular items in stock.

Can be used to search for the details of various
suppliers i.e., name, address, phone number
etc.
Produce the entire lists of products stocked
and supplied in seconds
Forecast stock levels needed on the basis of
previous sales
Produce sales reports and improves the
profitability.

DISADVANTAGES OF SCS

Automatic stock monitoring

Recognizing when a customer has bought a product.
Automatically signaling when more products need to be put
on the shelf from the warehouse.
Automatically reordering stock at the appropriate time.
Automatically producing management information reports.

THANK YOU
Any Ques.